Method and system for manufacturing composite structures of wind turbine blades

Abstract

The present invention relates to a system and method for manufacturing a composite structure (17) of a wind turbine blade (5). A layer of fibrous material (33) is placed in a mold (16), and the upper surface of the upper layer is scanned using a measuring device (25). Data input from the measuring device (25) is analyzed by a processor (26) to identify the location of defects (27) and their detailed information. The location data is then transmitted to an illumination system (28), where an illumination device (29) is used to visually indicate the location of the defects (27) on or relative to the upper layer of the composite structure (17). This inspection method can be performed during the dry lamination of each layer, thereby allowing for the correction of defects (27) before the injection of the resin matrix material.

Description

Technical Field

[0004] ,

[0001] The present invention relates to a method and a system for manufacturing a composite structure of a wind turbine blade. A measuring device is arranged above a mold having a forming surface, and the measuring device is arranged relative to a movable tool for laminating a fiber material layer onto the forming surface or on top of a preceding fiber material layer. The measuring device is connected to a processor, and the processor is configured to analyze data from the measuring device and identify the positions of defects in the layer or the preceding layer. The positions are visually indicated on or with respect to the layer.

Background Art

[0002] During the manufacture of large composite structures such as wind turbine blades, it is known for workers to manually inspect the lamination quality of the layers. However, this inspection process is laborious and time-consuming and requires highly trained personnel. Defects in the laminate or sandwich structure can affect the structural integrity after curing and may require additional repair work after manufacture. Visual inspection depends on the skills and knowledge of the operator and may lack reproducibility and accuracy.

[0003] EP 2390074 B1 discloses an in-line inspection method for manufacturing prepregs or laminates. In this method, during the manufacturing process, two measurements of the same parameter or different parameters of the prepreg or laminate are taken. The measurements may include optical two-dimensional measurements of the laminate surface topography during lamination using imaging techniques. The optical measuring device may be positioned adjacent to the lamination head. The captured image data is analyzed and evaluated by a processor to identify defects such as wrinkles in the prepreg or laminate.

[0004] Historical data of prepregs or laminates may be used as input information for a processor to predict whether identified defects exist in the cured portion of the prepreg or laminate, and how they affect the strength of the cured portion. The processed data may be used to automatically or manually adjust parameters related to the lamination process. However, details are not provided as to how the results of the data processing are presented to the operator or how the parameters of the lamination process are adjusted.

[0005] US 2013 / 0179118 A1 discloses a method and system for inspecting laminates of wind turbine blades, in which two optical measuring devices are positioned at both ends of a movable laminate trolley. These devices are connected to a computer, which generates a two-dimensional or three-dimensional data model of the top surface to identify defects in the laminate during lamination. This data model can also be compared to a data model generated after the curing of the composite material portion. Once defects are identified, it is suggested that the defects are isolated and removed. However, details of this removal process are not provided.

[0006] DE 102011051071 A1 discloses a method and imaging system for inspecting fiber laminates, wherein a transmitter emits electromagnetic waves toward the fiber laminate, and a receiver receives the waves reflected by or transmitted through the fiber laminate. An image recognition algorithm can be implemented on a computer to identify defects in the fiber laminate using the principle of synthetic aperture radar (SAR). The defects are then corrected before the resin matrix material is injected into the fiber laminate. The application suggests that the images are displayed to the operator, but no further details are provided.

[0007] EP 2991034 A1 provides a method and system for inspecting fiber laminates, with a light source and camera positioned above the mold. The light source projects a light pattern onto the mold, and the camera captures an image of the light pattern. A computer then generates a baseline three-dimensional profile of the mold. Each fiber layer is then laminated onto the mold. Another three-dimensional profile is generated by projecting light onto the fiber layer and capturing the reflected light pattern. The thickness difference between each three-dimensional profile is then calculated and compared to a threshold. If the error exceeds the threshold, an alert is generated and the defect is corrected. Details are not provided on how the alarm information is presented to the operator.

[0008] It is also known that a reference line is projected onto the mold or fiber layer using an overhead laser projection system. An example of such a laser projection system is disclosed in EP 3645255 A4. A computer model of the lamination sequence of the core panels is generated, from which reference markings for the placement of the core panels are extracted. The mold includes multiple reflective markings used to calibrate the laser projection system. Deviations between the projected markings and the core panels may lead to adjustments in the placement of the core panels or adjustments in the projected reference markings. The lamination process still requires manual or automated defect inspection.

[0009] EP 1955108 B1 discloses a method and system for projecting a defect image onto the surface of a workpiece using a laser projection device. The laser projection device is connected to a data system or database containing information indicating defects in the workpiece. The data system collects data about the workpiece using one or more sensors, which are then analyzed and evaluated by a computer. The data may also be downloaded to the database before the inspection is performed. Encoders and reflective targets are used to determine the orientation and position of the laser projection device and the rotation angle of the mandrel.

[0010] This configuration is suitable only for workpieces that rotate during manufacturing, as disclosed in EP 2918400 B1. Each layer is inspected, all defects are recorded in a database, and a structural integrity check is performed. If necessary, instructions for correcting defects are generated and sent to the worker. Information on the corrective work performed is stored in the database. This inspection system is specifically designed to work in conjunction with a rotating mandrel and a movable gantry positioned on rails adjacent to the mandrel. Adhesive tape strips are attached to the base material of the mandrel, and compression rollers press the tape strips against the base material for contact. Therefore, it cannot be implemented in conjunction with a wind turbine blade manufacturing system.

[0011] Other systems analyze the cured composite structure using optical inspection systems, such as those described in WO 2015 / 028023 A1 and US 8418560 B2. However, these systems increase post-manufacturing workload and the amount of waste. [Overview of the project]

[0012] One objective of the present invention is to overcome the problems of the prior art described above.

[0013] One objective of the present invention is to provide a method and system that enables an operator to quickly and easily identify defects within a laminated structure.

[0014] One object of the present invention is to provide a method and system that enables improved inspection of laminated structures.

[0015] One object of the present invention is to provide a flexible method and system that can be easily adapted to different manufacturing setups and / or interact with existing manufacturing setups. [Means for solving the problem]

[0016] One objective of the present invention is achieved by a system for manufacturing wind turbine blades. The system is - A mold having a molding surface, the molding surface being molded to form a composite structural profile of a wind turbine blade, - A movable support structure positioned relative to a mold, wherein the support structure is configured to move in at least one direction relative to the mold, - At least one measuring device positioned in a support structure, the at least one measuring device configured to scan at least the upper layer of the composite structure and measure topographic data relating to the upper surface of the upper layer. - A processor connected to at least one measuring device, the processor being configured to analyze data input from at least one measuring device and to determine whether or not a defect exists at least in the upper layer, the processor further comprising a processor configured to identify at least the location of the defect, The lighting system is further connected to a processor and positioned relative to the mold, and the location of at least a defect is transmitted to the lighting system, the lighting system comprising at least one lighting device configured to visually indicate the location of a defect at least on or relative to the upper layer.

[0017] This provides a simple and reliable in-line inspection system for monitoring the lamination process of dry fiber layers during the manufacturing of composite structures. The system is suitable for the manufacture of composite structures having laminated or sandwich structures. Furthermore, the system is suitable for interaction with manual or automated lamination systems and can function in cooperation with or independently of the lamination system.

[0018] This system may also be used to perform quality inspections of cured laminated or sandwich structures. This allows operators to quickly and easily identify defects in the cured composite structure that require repair during the post-cure process. The system allows the measuring device to move along the length of the wind turbine blade, and the lighting system to visually indicate defects on the composite structure.

[0019] Conventional robotic inspection systems are limited to automatically scanning the external profile of assembled wind turbines, with the scan results displayed on a computer terminal on a remote computer station or mobile platform. However, workers still need to manually identify defects on the external surface.

[0020] Here, the term “topographic data relating to the top surface” is defined as obtaining quantifiable two-dimensional or three-dimensional measurements of surface topographic features by non-contact scanning of the top surface. Measurement techniques include optical measurements, microscopic measurements, interferometry, or profile measurements. However, other methods for measuring surface topography can also be used.

[0021] The system's processor is configured to process input data from a measuring device and determine one or more parameters related to surface topography based on the input data. These parameters can be combined to form a two-dimensional or three-dimensional map of the surface topography. The processor is further configured to evaluate these parameters to identify defects in at least the upper layers, preferably using predetermined thresholds, design parameters, or other reference parameters stored in the processor and / or database. Defects may include wrinkles (in-plane or out-of-plane), voids, foreign matter, ply detachment, or other anomalies leading to distortion of the upper layer surface. This enables automated inspection of laminated or sandwich structures and allows for the detection of defects during production.

[0022] In one embodiment, the lighting device is formed as at least one row of light-emitting elements disposed on or positioned relative to the mold, and the light-emitting elements of each row extend at least along the length of the molding surface.

[0023] The system is connected to the lighting system of the processor via a wired or wireless communication link. The lighting system includes a number of lighting devices configured to emit one or more light beams that form one or more visually distinguishable patterns on or near the molding surface or the composite structure. The lighting device is directly or indirectly connected to the processor and is configured to receive data regarding the results of data analysis in the processor. The lighting device is configured to emit light based on the received data to visually indicate at least the position of defects and / or the position of non-defects. Thereby, an operator can quickly identify defects in the upper layer and take corrective measures as necessary.

[0024] The lighting device may be formed by light-emitting diodes (LEDs) disposed on the mold. Preferably, at least one row of first LEDs may be disposed on the first side of the mold, and / or at least one row of second LEDs may be disposed on the second side of the mold. The rows of first LEDs and second LEDs may extend along at least a part of the length of the molding surface, preferably along the entire length. Thereby, an operator can quickly and easily identify defects and / or non-defects in the longitudinal direction.

[0025] Optionally, at least one more row of third LEDs may extend in the lateral direction of the mold. The row of third LEDs may be disposed adjacent to the first LEDs and / or the second LEDs on the mold. Thereby, an operator can quickly and easily identify defects and / or non-defects in the lateral direction as well.

[0026] The number of LEDs may be selected based on the length and / or width of the composite structure. Each LED may define a section in the longitudinal direction and / or the lateral direction of the composite structure or the molding surface.

[0027] In one embodiment, the light emitting elements are grouped into at least one matrix disposed on or positioned relative to the mold, and each matrix of light emitting elements defines a plurality of sections in the longitudinal and / or transverse direction of the composite structure.

[0028] Alternatively, a matrix of first LEDs and / or a matrix of second LEDs may be disposed on the first side and / or the second side of the mold. The first LEDs and / or the second LEDs in each matrix may be aligned in rows and columns. Preferably, the matrix may be disposed relative to the mold surface or the mold edge. Optionally, at least one matrix of third LEDs may further be disposed on the upper surface of the mold, preferably adjacent to the matrix of first LEDs and / or the matrix of second LEDs. Thereby, the operator can visually display the current position data and / or the history data.

[0029] The rows or matrices of first LEDs, second LEDs and / or third LEDs may also be disposed on separate frames or support structures. The frame or support structure may be a self-standing unit or may be configured to be attached to the wall of the floor of the work area. The frame or support structure may be positioned relative to the mold so that the operator can visually recognize the LEDs when moving within or around the mold. Further, thereby, the operator can quickly and easily view the current position data of defects and / or non-defects in the composite structure during production, and optionally the history data.

[0030] In one embodiment, the lighting device is configured as at least one light projection device positioned above the mold, and the light projection device is configured to project at least one light beam onto the upper surface of the upper layer.

[0031] The lighting device may also be formed as a light projection device positioned above the mold. Each light projection device may be configured to emit an electromagnetic light beam that is detectable by the human eye or using a detectable element. The detectable element may be a photoreactive lens or smart glasses. Preferably, the emitted light is visible light having, for example, a wavelength of 400 nm to 700 nm and / or a frequency of 420 THz to 750 THz.

[0032] Each light projection device may be positioned above the mold, preferably in a fixed position or on a movable frame structure. Multiple light projection devices may be arranged within the work area relative to the mold so that the light projection devices can project a light beam onto the overall composite structure or molded surface. The light projection devices may be laser projectors, digital projectors, or other types of light projection devices. This allows the location of defects, unique codes associated with each defect, and / or other relevant data to be visually displayed on the top surface, so that the operator can quickly and easily identify defects and other relevant data without manually locating and marking these locations.

[0033] The lighting system may include a local optical controller connected to the lighting device via a wired or wireless link. The local optical controller may further be connected to a local data processing controller of the processor. The optical controller may be configured to control the operation of the lighting device and communicate with the data processing controller and / or database. The data processing controller may be configured to process data input from the measuring device and communicate with the optical controller and / or database. Alternatively, the optical controller and data processing controller can be implemented in a single control unit. This allows the system to be adapted to the production setup of the work area. Furthermore, this allows for faster data processing, thereby reducing the time delay between data input and data output.

[0034] This system can interact with existing projection systems that can receive and project the location of defects onto an upper surface, as described in EP 1955108 A1. This reduces the number of required system components and lowers costs. The light controller can optionally be implemented in the control unit of an existing projection system.

[0035] However, conventional lighting systems, such as those described in EP 3645255 A1, are typically configured only for projecting reference markings onto the core panel or fiber layer lamination.

[0036] In one embodiment, the processor is connected to at least one database configured to store at least historical data regarding defects in layers of a composite structure. The processor is further configured to process data input from at least one measuring device in real time and to continuously update the location data of defects in at least the upper layers.

[0037] The processor may be implemented in a local or remote control unit, and the control unit may be connected to a local or remote database. The processor and / or database may be implemented in a local or remote server unit. For example, the processor may be positioned as a local control unit communicating with a remote database unit. This enables stable data processing and data communication. Alternatively, the processor and database may be positioned as a remote server unit communicating with, for example, a local controller of a lighting system. This allows complex data processing to be performed remotely while the local controller controls the operation of the system and communication between its electrical components. Thus, the amount of local data processing is reduced.

[0038] The processor can process and analyze data input from the measuring device in real time or near real time. Here, "real time" includes processing the data as soon as it is received. "Near real time" includes collecting the measurement data in batches and processing the batches of measurement data. The batch size may be selected as a time interval or a length interval. Thus, the processor can identify defects at least at the upper layer in real time or near real time.

[0039] The processor is configured to at least determine the location of any identified defect in the longitudinal and / or widthwise directions. The location data of these defects in the upper layer may then be transmitted to and stored in a database. The location of the defects can be identified using a local collaborative system within the work area. The database may be continuously updated as the measuring device moves along the molding surface or after each run is completed. This allows for easy identification of defects in the current upper layer while updating historical data.

[0040] In one embodiment, at least one measuring device is configured to continuously measure data relating to surface topography as the support structure moves along the molded surface in at least one direction.

[0041] The processor may be connected to the measuring device via a wired or wireless link. The measuring device may be configured to continuously transmit data to the processor or to temporarily store data before transmitting it to the processor. The amount of data transmitted may vary depending on whether the data is processed locally or remotely. Optionally, raw data from the measuring device may also be transmitted to and stored in a database.

[0042] The measuring device may be configured to perform two-dimensional or three-dimensional measurements of surface topography in the longitudinal and / or transverse directions. For example, the measuring device may scan the top surface by emitting an electromagnetic signal onto the top surface using one or more transmitters. The measuring device may then capture the reflected signal using one or more receivers. Alternatively, one or more cameras may be used to capture one or more images of the top surface and any light patterns projected onto the top surface. These images may then be processed and analyzed by a processor. The measuring device can measure the features of the top surface using non-destructive imaging techniques such as ultrasound, X-ray, tomography, shapemetry, digital imaging, electromagnetic radiation, or other measurement techniques.

[0043] The processor may be configured to process measurement data to determine one or more parameters related to the defect, as described later. The parameters may include variations in top surface height, variations in top layer thickness, top layer misalignment, edge detection, and other related parameters. The processor may also be configured to determine a Critical To Quality (CTQ) level or severity index associated with the defect. The CTQ level and / or severity index may also be visually indicated on or near the molded surface or composite structure using an illumination device.

[0044] In one embodiment, at least one lighting device is configured to visually indicate the location of a defect using at least one set of colors, and optionally to visually indicate the location of a defect-free area using at least one additional set of colors.

[0045] The lighting device may be configured to emit a light pattern having one or more colors to visually indicate the location of defects and / or defects. A first set of colors may be used to visually indicate the location of defects identified by the processor. Optionally, a second set of colors may be used to visually indicate the location of defects. Alternatively, no light may be used to visually indicate the location of defects. This allows the operator to quickly identify defects in the composite structure by the colors used.

[0046] The location of a defect can be visually indicated using continuous light of a selected color with a constant intensity. Alternatively, the location of a defect can be visually indicated using alternating light. Alternating light can be created by emitting selected colors at different intensities. Alternatively, alternating light can be created by emitting different colors at the same intensity. Alternatively, alternating light can be created by emitting different colors at different intensities. This allows the worker to quickly identify the defect and, optionally, its detailed information.

[0047] In one embodiment, at least one lighting device is configured to visually indicate the location where defects and / or defects are identified by emitting continuous light, alternating light and / or rhythmic light having at least one light period and at least one dark period.

[0048] The lighting device may be configured to further emit light patterns with continuous or alternating light, as described above. Alternatively, the light patterns may be emitted using rhythmic light having at least one light period and at least one dark period, where the light and dark periods may be selected to indicate the type and / or severity of the defect. The use of rhythmic light can be combined with the use of different colors and / or continuous or alternating light. This allows the worker to further identify details of the defect by using the selected type of light.

[0049] Optionally, the above light patterns may also be adapted to visualize chord-direction positions on a surface area. This allows the operator to quickly and easily identify selected chord-direction positions using the light patterns.

[0050] In one embodiment, the processor is configured to identify the type and / or severity of a defect, and preferably the processor is further configured to rank the type and / or severity of a defect according to one or more predetermined conditions.

[0051] The processor may be configured to classify the parameters of identified defects according to predetermined conditions that define a number of ranking levels. Each ranking level may be associated with the type of defect, the severity of the defect, the size of the defect, and / or the CTQ level. Each ranking level may be further linked to a specific light color, rhythmic light, and / or continuous or alternating light. This enables the automatic classification of identified defects and makes it visually clear how severe the defects are.

[0052] The processor may be configured to identify ply detachment, misalignment, or edge detection in the upper layer (or multiple upper layers) based on measurements. These defects are classified as non-critical defects and may therefore be visually indicated using a specific type of light different from other types of light. Thus, non-critical defects can be identified quickly and easily and distinguished from other defects.

[0053] In one embodiment, the system further includes at least one lamination tool configured to move in at least one direction relative to the mold, the lamination tool configured to apply at least one fibrous material layer to the molded surface or upper layer.

[0054] The system may further include one or more laminating tools configured to apply one or more layers of fiber material to the upper layer. The fiber material may be supplied from a roll. The laminating tools may be positioned on a laterally extending trolley. The trolley may be movable longitudinally along a pair of rails. The pair of rails may be positioned along the side of a mold or adjacent to the mold. Alternatively, the trolley may be configured to move along a pair of rails positioned on a runway beam above the work area. The laminating tools may further be movable laterally along the trolley and / or vertically relative to the trolley. This enables at least semi-automatic lamination of various fiber layers, thus reducing the total lamination time and providing a less labor-intensive process.

[0055] The trolley may include a dual lamination tool capable of applying fiber layers in both longitudinal directions. Each individual lamination tool can be fed from an individual fiber material roll. Since each individual lamination tool can be operated independently, the lamination process can be performed in both longitudinal directions. This further reduces the total lamination time.

[0056] The lamination tool may be configured to connect directly to a cart on rails, a robotic arm, or a beam in a crane system. The crane system may be a gantry crane or an overhead crane. The lamination tool may form part of a semi-automatic or automatic lamination system. The lamination tool may move along the forming surface in the longitudinal and / or transverse directions. This allows for the application of layers using an automatic or semi-automatic lamination process, thus reducing overall production time and minimizing the risk of defects due to human error.

[0057] The stacking tool or trolley may include a position sensor configured to measure the position of the stacking tool. The position sensor may be connected to a processor via a communication link. The processor can determine the position of the stacking tool based on the input from the position sensor.

[0058] In one embodiment, the support structure forms part of the stacking tool, and the measuring device is connected to the stacking tool so as to follow the movement of the stacking tool.

[0059] The measuring device can be connected to a lamination tool or trolley, so that it follows the movement of the lamination tool or trolley. The processor can determine the position of the measuring device using data input from position sensors on the lamination tool or trolley. Optionally, at least a data processing controller may be located on the lamination tool or trolley. This allows scanning of the upper layers while applying the fiber layers in combined operation.

[0060] The first measuring device may be positioned at one end of the dual lamination tool, and the second measuring device may be positioned at the opposite end of the dual lamination tool. Both the first and second measuring devices may be connected to a processor. This allows the surface to be scanned in both longitudinal directions as the lamination tool moves.

[0061] In one embodiment, the support structure is molded as a beam or frame configured to be connected to a crane system, trolley, or transport system. The crane system, trolley, or transport system is configured to move the beam or frame further in at least one direction relative to the mold, and preferably, the crane system, trolley, or transport system is configured to move the beam or frame independently of the lamination tool.

[0062] The measuring device may also be positioned on a support structure configured to be connected to a crane system or trolley on which the lamination tool is located. Alternatively, the support structure may move along a separate crane system, trolley, or transport system further positioned relative to the mold. The transport system may be an automated guided vehicle (AGV) system. Thus, the support structure with the measuring device may be positioned to move independently of the lamination tool. This allows the scanning of the upper layers and the lamination of the fiber material to be performed as separate, independent processes. For example, scanning can be performed between the lamination of fiber layers.

[0063] Conventional inspection systems use a mobile platform (e.g., a self-propelled vehicle) equipped with a movable holder (e.g., a robotic arm) to position and orient a 3D scanner or scanning probe relative to the hardened composite structure. However, this increases the complexity of the entire system and requires moving the composite structure to the finishing area.

[0064] In one embodiment, a single measuring device or at least two measuring devices are arranged laterally on a support structure, and the measuring devices are positioned on the support structure in a fixed or adjustable position and / or orientation.

[0065] Preferably, the measuring device is an optical measuring device such as a distance sensor, or a profilometer configured to scan at least the upper surface of the upper layer. The optical measuring device or profilometer may include at least one light source for illuminating the upper layer. For example, a laser source or a digital light source can be used to project one or more patterns onto the upper surface. The optical measuring device or profilometer may further include at least one camera for capturing an image of the inspection area. This provides an inexpensive and reliable surface topography measurement.

[0066] The processor may be configured to determine parameters for top topography and / or two-dimensional or three-dimensional surface profiles based on data input from an optical measuring device or profiler. The processor can identify defects using a base model that defines nominal surface lines or profiles in the longitudinal and / or transverse directions. This enables simple, reliable, and automated detection of defects in the processor.

[0067] This system can scan the entire width of a composite structure or molded surface using a single measuring device. Alternatively, two or more measuring devices can be positioned relative to each other and used to scan the entire width of the composite structure or molded surface. This allows the configuration of the measuring device setup to be adapted to the dimensions and geometric profile of the composite structure.

[0068] The measuring device may preferably be positioned on a support structure so as it moves along the mold, it can scan the entire top surface of the composite structure. Each measuring device can be connected to the support structure in a fixed position and orientation so that it follows the movement of the support structure. Alternatively, the measuring device can be configured to rotate about a local transverse axis and / or a local longitudinal axis so that it can be precisely oriented with respect to the inspection area of ​​the top surface. This allows the measuring device to adjust the geometric profile of the molded surface or composite structure during scanning.

[0069] In one embodiment, the system further includes at least one feedback device configured to input a feedback signal to a processor, the feedback device being configured to communicate with the processor directly or via a measuring device or lighting system.

[0070] This system may further include one or more feedback devices. Therefore, operators can quickly and easily input feedback signals without manually entering information into a central terminal.

[0071] The feedback device may be one or more buttons (such as push buttons) arranged along a row of LEDs. These buttons may be distributed along the length of the LEDs and may be connected to a processor to input one or more feedback signals. The feedback signals may, for example, indicate approval of a selected portion of the upper layer. This allows the operator to input feedback signals quickly and easily.

[0072] The feedback device may be one or more handheld devices configured to communicate with the processor via a wireless or wired communication link, such as a smartphone, phablet, tablet, or remote controller. A user interface (GUI) on the handheld device may be used to input feedback signals and / or receive detailed information about the selected defect. Optionally, the handheld device may be configured to scan a selected unique code displayed on its top surface. This allows the operator to quickly and easily input feedback signals and view detailed information.

[0073] Alternatively, the feedback device may be one or more smart glasses configured to communicate with the processor via a wireless or wired communication link. The smart glasses may be configured to receive defect-related data from the processor, such as location data, historical data, corrective action instructions, or other relevant data. This allows the worker to receive detailed information about the selected defect while continuing to interact with the composite structure. The worker can input feedback signals via the smart glasses. The feedback signals may be sent back to the processor. This also allows the worker to input feedback signals quickly and easily and view detailed information.

[0074] Alternatively, the feedback device may be one or more reflectors configured to reflect the feedback signal back to the optical projector. Each reflector may include a unique code incorporated into its reflection pattern. A processor or optical controller may be configured to detect the reflected signal and decode the feedback signal. This allows the operator to input the feedback signal simply by positioning the reflectors in the illustrated area on the top surface.

[0075] In one embodiment, the composite structure includes a spur cap, a shear web, a trailing edge reinforcement, a leading edge reinforcement, and a blade shell portion or blade root portion.

[0076] This system is suitable for use in manufacturing large composite structures such as wind turbine blades. The molding surface of the mold may be formed to form wind turbine blade components. Wind turbine blade components may include spur caps, shear webs, trailing edge reinforcements, leading edge reinforcements, suction-side blade shells, pressure-side blade shells, or blade root sections.

[0077] This system can be integrated into existing automated stacking systems to reduce the number of parts and lower installation costs. Alternatively, it may be implemented as a standalone inspection system.

[0078] One object of the present invention is also achieved by a method for manufacturing wind turbine blades. The method is - A step of arranging layers of a composite structure of wind turbine blades on the molding surface of a mold, wherein the composite structure has a laminated structure or a sandwich structure, - The steps include scanning at least the upper layer of the composite structure using at least one measuring device and transmitting topographic data relating to at least the upper surface of the upper layer to a processor, - A step of analyzing data input from a measuring device using a processor, wherein the processor determines whether a defect exists at least in the upper layer, and further identifies at least the location of the defect. - A step of transmitting at least the location of a defect to a lighting system, the step of visually indicating the location of the defect to or from the upper layer using the lighting system.

[0079] This provides an improved method for inspecting the composite structure of wind turbine blades, which can be used during the lamination of the dry layer of the composite structure and in the post-curing process. The method may be implemented in combination with existing automated lamination systems to save on installation costs and reduce the total number of parts.

[0080] The top surface is scanned as the measuring device moves along the molded surface or composite structure. Next, data from the measuring device is processed and analyzed by a processor, which then transmits at least defect location data to the illumination system. The illumination system visually indicates the location of these defects to the operator, allowing for rapid identification of defects in the upper layers and repair as needed.

[0081] Conventional automated inspection systems are limited to scanning assembled wind turbine blades in the finishing step. The platform is mounted along the floor and scans the outer surface of the wind turbine blade. The scan results are displayed in real time on a computer terminal on the platform or on a remote computer station. Information about defects must be communicated to the operator manually or via a handheld computer device, and the operator must manually find and repair these defects before coating.

[0082] Other conventional inspection systems utilize portable, handheld scanner tools that scan small surface areas and project the results onto the surface using color.

[0083] In one embodiment, light-emitting elements of an illumination system are used to visually indicate the location of defects along the length of the mold. The light-emitting elements define multiple sections of the composite structure in the longitudinal and / or transverse directions.

[0084] The rows of the first and / or second LEDs in the matrix can be used to visually indicate the current location of defects and / or defects across the entire upper layer. Alternatively, the rows of the first and / or second LEDs in the matrix can be used to visually indicate historical data of defects and / or defects in one or more layers. The LEDs may be positioned on the mold or on a separate frame or support structure positioned relative to the mold. This allows the operator to visually view the location and / or historical data of defects in the upper layer during lamination or the post-curing process.

[0085] The LEDs can be positioned on existing molds and assembled to the desired length in a quick and easy manner, allowing for quick and simple installation.

[0086] In one embodiment, at least one light projection device of the lighting system is used to visually indicate the location of defects on the upper surface of the upper layer. The light projection device projects at least one light pattern onto the upper surface of the upper layer.

[0087] Furthermore, by projecting light patterns from the light projection device, the location of defects on the upper surface can be visually indicated. Each light projection device can project one or more light patterns within the projection area of ​​the upper surface, and thus, the operator can visually identify multiple defects in the upper layer. Preferably, the combined projection area of ​​the light projection devices may correspond to at least the entire upper surface of the composite structure.

[0088] The light pattern may be the boundary around the defect, the local width and length of the defect, and / or the surface area of ​​the defect. Other light patterns may also be used. The illuminated light pattern can be corrected according to the angle between the light projection device and the upper surface.

[0089] If light projection devices are already installed above the work area, these light projection devices may be used to visually indicate the location of defects. Next, this light controller can be implemented on or communicate with an existing light controller. This allows for the visual display of defects and lamination patterns on the upper surface.

[0090] In one embodiment, a processor analyzes the data in real time, and / or a lighting system visually indicates the location of defects in real time.

[0091] Data from the measuring device may be transmitted to a processor and processed in real time. The raw data from the measuring device may optionally be stored in a database. The processor may determine surface topography parameters in real time and further identify defects in real time, at least in the upper layers. Defect location data, defect type, defect severity, and other historical data may be continuously stored in the database. This allows for real-time defect identification.

[0092] Defect location data, historical data, and other data are transmitted to the lighting system, which may visually display the defect location and optionally other data in real time. This allows workers to quickly isolate defects, at least in the upper layers of the composite structure, and initiate repairs. This saves manufacturing time by allowing corrective measures to be taken during dry lamination.

[0093] In one embodiment, defects are ranked by the processor according to one or more predetermined conditions, and each ranking level is associated with a different color set and / or a different rhythm frequency.

[0094] The processor may evaluate measured surface topography parameters to provide detailed information about the identified defects. Defects may be classified according to predefined ranking criteria, such as defect height, width and / or length, defect type, defect severity, or other conditions. Each ranking level may be associated with a set of illumination light colors, rhythm frequency and / or intensity. This allows the operator to visually see the details of the defect through the illumination light and / or light pattern.

[0095] This detailed information reduces the need to manually evaluate each defect, allowing workers to take corrective actions for each defect more effectively.

[0096] In one embodiment, the composite structure extends from a first end to a second end in the longitudinal direction and further extends from a first edge to a second edge in the width direction. A scan of the top surface is performed as the measuring device moves along the longitudinal direction. Here, the scan is performed over at least a portion of the width of the composite structure and / or over at least a portion of the length of the composite structure.

[0097] The scan may be performed along only a portion of the entire surface area, preferably along the surface area of ​​the upper layer where the next fiber layer is to be placed, or along a significant portion of the surface area. Alternatively, the scan may be performed across another surface area of ​​interest. The measuring device may operate two or more times to scan the entire surface area of ​​a selected layer of the composite structure. Alternatively, the entire surface area of ​​a selected layer of the composite structure can be scanned in a single operation. Historical data can be updated after each operation or continuously. This allows for flexible scanning of the upper surface.

[0098] The orientation of the measuring device can be adjusted longitudinally and / or transversely to accurately orient the device relative to the top surface during scanning. This adjustment can be performed manually or automatically.

[0099] In one embodiment, at least one fiber material layer is laminated on top, and the top surface is scanned at the same time.

[0100] The scanning of the top surface and the lamination of the fiber layer may be performed simultaneously in a combined step. Depending on the position of the measuring device, the measuring device may scan the former top layer immediately before lamination, or it may scan the latter layer after lamination. This reduces the total number of production steps.

[0101] Placing layers of a composite structure on a molding surface involves laminating multiple fibrous material layers onto the molding surface of a mold. These layers together form the composite structure of a wind turbine blade. The fibrous material layers can form a laminate of the inner skin, outer skin, and / or layers of the composite structure. This allows scanning to be performed during the dry lamination of each layer forming the composite structure. This improves the lamination quality and reduces the total number of defects that occur in the composite structure after curing.

[0102] In one embodiment, a scan of the top surface is performed after laminating at least one fiber material layer on top, and optionally before laminating at least one other fiber material layer.

[0103] Placing layers of a composite structure on a molding surface includes laminating all layers of the composite structure, injecting resin matrix material into the layers, and curing the injected layers to form a cured structure. This allows scanning of the cured composite structure to be performed during the post-curing process.

[0104] This scanning process can be performed while the cured composite structure is still inside the mold, or after the cured composite structure has been moved to the finishing area. This allows the same inspection system to be used during lamination and after curing, thereby increasing the flexibility of the system and reducing costs.

[0105] In one embodiment, the method further includes the step of inputting at least one feedback signal to a processor, preferably via a graphical user interface. The feedback signal indicates that at least one predetermined action has been performed with respect to a selected defect.

[0106] As described above, operators can input electronic feedback signals into the system using handheld or mobile devices. The user interface of the handheld or mobile device may be configured to allow for quick and easy input of feedback signals. The feedback signals may be false detection signals, corrective action completion signals, monitoring continuation signals, or other feedback signals. This allows for quick and easy input of feedback signals.

[0107] The operator may input a feedback signal using a reflective feedback device with an integrated unique code. The feedback signal can be input simply by positioning the reflector over a selected defect within the illumination area of ​​the light projector. The processor may then read the reflected code and store the feedback signal along with the details of the defect.

[0108] The worker can also input feedback signals via smart glasses. These feedback signals may be sent back to the processor. Feedback signals can be input to the smart glasses using voice commands or push buttons. Optionally, the smart glasses may be configured to scan the top surface and detect a light pattern projected onto the upper layer. The light pattern may be a unique code (barcode or 2D code) and / or the location of a defect. This enables a hands-free workflow during production.

[0109] In one embodiment, after each scan, historical data regarding defects in a specific layer of the composite structure is stored in a database, and preferably, feedback signals input to the processor are further stored in the database.

[0110] Data from the measuring device may be stored in a database. Data regarding defects in that layer may also be stored in the database. This data may be updated each time the measuring device is operated. Any feedback signals may also be stored in the database.

[0111] Further details regarding corrective measures may be stored in a database. This information can be accessed via a handheld or mobile device or smart glasses.

[0112] In one embodiment, a processor transmits historical data regarding defects in at least one preceding layer to the lighting system, and the lighting device visually displays the historical data together with current data regarding defects in the upper layer, preferably.

[0113] The historical data can be visually displayed in first-in, first-out (FIFO) order, and it is preferable to update it after each operation of the measuring device. Alternatively, the historical data can be displayed visually upon request. Or, the historical data can be visually displayed by switching between different historical data after a predetermined period. This allows the operator to visually see the historical data of interest.

[0114] Historical data and / or detailed information may also be displayed in the user interface in real time or near real time. This allows the results of data processing to be displayed to the operator quickly and easily. [Brief explanation of the drawing]

[0115] The present invention will be described by illustration only with reference to the drawings. [Figure 1] An exemplary embodiment of a wind turbine is shown. [Figure 2] An exemplary embodiment of a wind turbine blade is shown. [Figure 3] A first embodiment of a system for manufacturing a composite structure for wind turbine blades is shown. [Figure 4] This shows a conventional trolley with a mold and dual lamination tools. [Figure 5] An exemplary embodiment of a trolley equipped with a dual stacking tool according to the present invention is shown. [Figure 6] An exemplary embodiment of a light beam projected onto the upper surface is shown. [Figure 7] Figures 7a and 7b show two alternative configurations of the measuring device on the support structure. [Figure 8] The image shows a trolley moving along the molding surface while visually displaying defects in real time. [Figure 9] This shows the matrix of light-emitting devices arranged on the mold. [Figure 10] This shows a matrix of light-emitting devices arranged on separate support structures. [Figure 11] This shows a feedback device that interacts with a light pattern projected onto the upper surface of the upper layer.

[0116] The following sections will explain each figure in turn. Different parts or locations within a figure may be indicated by the same reference number in different figures. Not all parts or locations shown in a particular figure are necessarily explained in conjunction with that figure. [Modes for carrying out the invention]

[0117] Figure 1 shows an exemplary embodiment of a wind turbine 1. The wind turbine 1 includes a wind turbine tower 2, a nacelle 3 located at the top of the wind turbine tower 2, and a rotor connected to a drivetrain within the nacelle 3. The rotor includes a hub 4 and at least one wind turbine blade 5 connected to the hub 4. Here, three wind turbine blades 5 are shown, but the hub may be connected to more or fewer wind turbine blades.

[0118] Although the wind turbine 1 is shown as an onshore wind turbine, the wind turbine 1 may also be an offshore wind turbine 1. The wind turbine blades may be continuous wind turbine blades or modular wind turbine blades.

[0119] Figure 2 shows the blade shell 6 of a wind turbine blade 5. Here, the blade shell 6 has a pressure side 9 and a suction side 8. As shown in Figure 1, the blade shell 6 extends along the length direction between a first end 10 (e.g., root) and a second end 11 (e.g., tip). As shown in Figure 2, the blade shell 6 further extends along the chord direction between a first edge 12 (e.g., leading edge) and a second edge 13 (e.g., trailing edge).

[0120] The spur cap 14 is bonded to or integrated with the blade shell portion forming the pressure side 9. Furthermore, another spur cap 14 is bonded to or integrated with the blade shell portion forming the negative pressure side 8. One or both of the spur caps 14 may be formed as a single continuous spur cap or as a segmented spur cap. The segmented spur cap may optionally be joined at or near the second end 11.

[0121] Between the spur caps 14, shear webs 7 extend in the thickness direction. The shear webs 7 are bonded or integrated with the spur caps 14 at their respective web interfaces. The shear webs 7 may be formed as a single shear web or as a dual shear web. The dual shear webs may be spaced apart in the chord direction.

[0122] Optionally, one or more reinforcing webs 15 are further positioned within the blade shell 6. The reinforcing webs 15 are positioned at a certain distance from the first edge 12 and / or the second edge 13. The reinforcing webs 15 are bonded or integrated with the blade shell portions that form the pressure side 9 and / or negative pressure side 8.

[0123] Figure 3 shows a first embodiment of a system for manufacturing a composite structure of a wind turbine blade 5. The system includes a mold 16 having a molded surface formed to form the profile of a composite structure 17. The composite structure 17 extends longitudinally 20 between a first end 18 and a second end 19, and therefore the molded surface extends longitudinally 20 between the first end 18 and the second end 19. The composite structure 17 further extends widthwise 23 between a first edge 21 and a second edge 22, and therefore the molded surface further extends widthwise 23 between the first edge 21 and the second edge 22.

[0124] The movable support structure 24 is positioned relative to the mold 16 and is configured to move in at least one direction 20, 23 relative to the mold 16. At least one measuring device 25 is positioned on the support structure 24 and is configured to scan at least the upper layer of the composite structure 17 and measure surface topographic data relating at least the upper surface of the upper layer.

[0125] The processor 26 is connected to the measuring device 25 via a communication link. The processor 26 is configured to analyze the data input from the measuring device 25 and determine whether or not a defect 27 exists at least in the upper layer. The processor 26 is further configured to identify at least the location of the defect. Preferably, the processor 26 is configured to determine the location, severity, and / or type of the defect 27. Historical data and other data regarding the defect 27 are optionally stored in a database 31 connected to the processor 26 via a communication link.

[0126] The lighting system 28 is connected to the processor 26 via a communication link. The lighting system 28 includes a number of lighting devices 29, each positioned relative to the mold 16. The location of at least the defects 27 is transmitted from the processor 26 to the lighting system 28, for example, the light controller 30. The lighting devices 29 are configured to visually indicate the location of the defects 27 at least on or relative to the upper layer.

[0127] Optionally, the system includes a lamination tool 32 configured to be directly or indirectly connected to a crane system (not shown) positioned relative to the mold 16. The lamination tool 32 includes a roll of fiber material 33 and is configured to apply a fiber layer to the molded surface or upper layer. The applied fiber layer forms part of the laminated or sandwich structure of the composite structure 17 in the height direction 34. The crane system is configured to move the lamination tool 32 relative to the mold 16 in at least one direction 20, 23.

[0128] Here, the support structure 24 is formed as a beam configured to be connected to a crane system. The crane system is configured to move the beam further in at least one direction 20, 23 relative to the mold 16. Preferably, the crane system is configured to allow independent movement of the beam and the lamination tool 32.

[0129] The lamination tool 32 and the support structure 24 can optionally be joined together to form a composite structure. Therefore, the measuring device 25 follows the movement of the lamination tool 32.

[0130] Figure 4 shows a mold 16 and a conventional trolley 35 equipped with a dual lamination tool. The trolley 35 is positioned on a pair of tracks 36 extending along the mold 16. Thus, the trolley 35 is movable along the longitudinal direction of the molding surface 37. A first lamination tool, equipped with a first roll of fiber material 33, is used to apply a fiber layer in one longitudinal direction. A second lamination tool, equipped with a second roll of fiber material 33, applies a fiber layer in the opposite longitudinal direction.

[0131] Figure 5 shows an exemplary embodiment of a trolley 35' equipped with a dual stacking tool according to the present invention. The trolley 35' includes a position sensor (not shown) connected to a processor 26. The processor 26 determines the position of the trolley 35' based on data input from the position sensor.

[0132] The first measuring device 25a is positioned at one end of the trolley relative to the first stacking tool. The second measuring device 25b is positioned at the opposite end of the trolley relative to the second stacking tool. Here, the first measuring device 25a and the second measuring device 25b are configured as optical measuring devices. The configuration of optical measuring devices is known to those skilled in the art, so a detailed explanation is omitted.

[0133] Figure 6 shows an exemplary embodiment of a light beam 38 projected onto the upper surface of the upper layer. Here, the optical measuring device projects a light beam, such as a laser beam, detectable by a camera positioned within the optical measuring device. The light beam 38 extends along the entire width of the composite structure 17.

[0134] Figures 7a and 7b show two alternative configurations of the measuring device 25 on the support structure 24. As shown in Figure 7a, a single measuring device 25' is positioned on the support structure 24. The measuring device 25' is configured to scan a portion of the upper layer in the width direction 23. The measuring device 25' is connected to the support structure in an adjustable position. For example, the measuring device 25' can be moved along the support structure 24 in the width direction 23 to adjust its position relative to the mold 16. For example, the measuring device 25' can be rotated around a local length axis to adjust its orientation relative to the mold 16.

[0135] As shown in Figure 7b, two measuring devices 25'' are positioned on the support structure 24. Each measuring device 25'' is configured to scan a portion of the upper layer in the width direction 23. The data from the measuring devices 25'' are superimposed to form a combined set of data within the processor.

[0136] Figure 8 shows a trolley 35' moving along the molding surface 37 while visually displaying defects 27 in real time. The processor 26 processes the data input from the measuring device 25 in real time and ranks the defects 27, 27' according to predetermined conditions. The light-emitting element 29b is used to visually indicate the locations of defects 27, 27' and the locations of defect-free parts 40.

[0137] Severe defects 27 may be visually indicated using a first light having a selected color, intensity and / or frequency. Less severe defects or present defects 27' may be visually indicated using a second light having a selected color, intensity and / or frequency. Optionally, defect-free 40 may be visually indicated using a third light having a selected color, intensity and / or frequency. Alternatively, defect-free 40 may be visually indicated by turning off the light.

[0138] Figure 9 shows the matrix of light-emitting devices 29b arranged on the mold 16. The matrix of light-emitting devices 29b arranged in columns and rows is located on the side of the mold 16. Optionally, another matrix of light-emitting devices 29b arranged in columns and rows is located on the top surface of the mold 16.

[0139] The matrix of the light-emitting device 29b is used to visually display the historical data of defects 27 in the composite structure 17. The matrix of the light-emitting device 29b is optionally used to visually display the chord-direction position of the defects 27.

[0140] Figure 10 shows the matrix of the light-emitting devices 29b. Each light-emitting device 29b defines a section of the composite structure 17 in the length direction 20 and the width direction 20, 23. The matrix of the light-emitting devices 29b is optionally placed on a separate frame structure positioned relative to the mold 16.

[0141] The number of individual rows and columns is adjusted to match the geometric dimensions of the composite structure 17. Here, the first row of light-emitting devices 29b represents the trailing edge region. The second row of light-emitting devices 29b represents the intermediate region between the trailing edge region and the spur cap region. The third row of light-emitting devices 29b represents the spur cap region. The fourth row of light-emitting devices 29b represents the intermediate region between the spur cap region and the leading edge region. The fifth row of light-emitting devices 29b represents the leading edge region.

[0142] Figure 11 shows a feedback device 43 interacting with a light pattern 43 projected onto the upper surface of the upper layer. The light projection device 29a projects a light pattern indicating the location of the defect 27 onto the upper layer of the composite structure 17. The light projection device 29a optionally further projects a unique code 41 associated with that defect 27. The unique code 41 is linked to detailed information about the defect 27 stored in the database 31.

[0143] The feedback device 43 may be a handheld communication device such as a smartphone or smart glasses, configured to scan the unique code 41 and display detailed information stored in the database 31 to the user. The handheld communication device is connected to the processor 26 via a communication link.

[0144] The feedback device 43 may be a reflector in which a unique code is incorporated into the reflection pattern. The reflector is positioned within the illustrated region 42 of the light projection device 29a. The light projection device 29a is configured to detect the reflection signal from the reflector. The processor 26 reads the unique code and executes an instruction associated with this unique code. The instruction may store the feedback signal along with data about a defect 27, for example.

Claims

1. A system for manufacturing wind turbine blades (5), - A mold (16) having a molding surface (37), wherein the molding surface (37) is molded to form the profile of the composite structure (17) of the wind turbine blade (5), - A movable support structure (24) positioned relative to the mold (16), wherein the support structure (24) is configured to move in at least one direction relative to the mold (16), - At least one measuring device (25) positioned on the support structure (24), wherein the at least one measuring device (25) is configured to scan at least the upper layer of the composite structure (17) and measure topographic data relating at least the upper layer. - A processor (26) connected to the at least one measuring device (25), wherein the processor (26) is configured to analyze the data input from the at least one measuring device (25) and to determine whether or not a defect (27) exists in at least the upper layer, and the processor (26) is further configured to identify the location of at least the defect (27), A lighting system (28) is further connected to the processor (26) and positioned relative to the mold (16), the location of at least the defect (27) is transmitted to the lighting system (28), and the lighting system (28) includes at least one lighting device (29) configured to visually indicate the location of the defect (27) at least on or relative to the upper layer.

2. The system according to claim 1, wherein the lighting device (29) is molded as at least one row of light-emitting elements (29b) positioned on or relative to the mold (16), and each row of light-emitting elements (29b) extends at least along the length of the molded surface (37).

3. The system according to claim 2, wherein the light-emitting elements (29b) are arranged on the mold (16) or grouped into at least one matrix positioned relative to the mold (16), and each matrix of the light-emitting elements (29b) defines a plurality of sections in the longitudinal and / or transverse directions of the composite structure (17).

4. The system according to any one of claims 1 to 3, characterized in that the lighting device (29) is molded as at least one light projection device (29a) positioned above the mold (16), and the light projection device (29a) is configured to project at least one light beam onto the upper surface of the upper layer.

5. The system according to any one of claims 1 to 4, wherein the processor (26) is connected to at least one database (31) configured to store at least historical data relating to defects (27) in the layers of the composite structure (17), and the processor (26) is further configured to process the data input from the at least one measuring device (25) in real time and to continuously update the location data of at least the defects (27) in the upper layers.

6. The system according to any one of claims 1 to 5, wherein the at least one measuring device (25) is configured to continuously measure data relating to surface topography as the support structure (24) moves along the molded surface (37) in at least one direction.

7. The system according to any one of claims 1 to 6, wherein the at least one lighting device (29) is configured to visually indicate the location where a defect (27) is identified using at least one set of colors, and optionally further to visually indicate the location where no defect (40) is identified using at least one additional set of colors.

8. The system according to any one of claims 1 to 7, characterized in that the at least one lighting device (29) is configured to visually indicate the location where defects (27) and / or defects (40) are identified by emitting continuous light, alternating light and / or rhythmic light having at least one light period and at least one dark period.

9. The system according to any one of claims 1 to 8, wherein the processor (26) is configured to identify the type and / or severity of the defect (27), and preferably the processor (26) is further configured to rank the type and / or severity of the defect (27) according to one or more predetermined conditions.

10. The system according to any one of claims 1 to 9, further comprising at least one lamination tool (32) configured to move in at least one direction relative to the mold (16), wherein the lamination tool (32) is configured to apply at least one layer of fibrous material (33) to the molded surface (37) or the upper layer.

11. The system described in 10 is characterized in that the support structure (24) forms part of the stacking tool (32), and the measuring device (25) is connected to the stacking tool (32) and follows the movement of the stacking tool (32).

12. The system according to 10, wherein the support structure (24) is formed as a beam or frame configured to be connected to a crane system, trolley or transport system, the crane system, trolley or transport system is configured to further move the beam or frame in at least one direction relative to the mold (16), preferably the crane system, trolley or transport system is configured to move the beam or frame independently of the lamination tool (32).

13. The system according to any one of claims 1 to 12, characterized in that a single measuring device (25) or at least two measuring devices (25) are arranged laterally on the support structure (24), and the measuring devices are arranged on the support structure (24) in a fixed or adjustable position and / or orientation.

14. The system according to any one of claims 1 to 13, further comprising at least one feedback device (43) configured to input a feedback signal to the processor (26), wherein the feedback device (43) is configured to communicate directly with the processor (26) or to communicate with the processor (26) via the measuring device (25) or the lighting system (28).

15. The system according to any one of claims 1 to 14, characterized in that the composite structure (17) is a spur cap (14), a shear web (7), a trailing edge reinforcement (15), a leading edge reinforcement (15), a blade shell portion, or a blade root portion.

16. A method for manufacturing wind turbine blades (5), - A step of arranging the layers of the composite structure (17) of the wind turbine blade (5) on the molding surface (37) of the mold (16), wherein the composite structure (17) has a laminated structure or a sandwich structure, - The steps include scanning at least the upper layer of the composite structure (17) using at least one measuring device (25) and transmitting topographic data relating at least the upper surface of the upper layer to a processor (26), - A step of analyzing the data input from the measuring device (25) with the processor (26), wherein the processor (26) determines whether or not a defect (27) exists in at least the upper layer, and further identifies at least the location of the defect (27), A method comprising the steps of: transmitting the location of at least the defect (27) to a lighting system (28), wherein the lighting system (28) is used to visually indicate the location of at least the defect (27) to or from the upper layer.

17. The method according to 16, characterized in that the light-emitting element (29b) of the lighting system (28) is used to visually indicate the location of the defect (27) along the length of the mold (16), and the light-emitting element (29b) defines a plurality of sections of the composite structure (17) in the longitudinal and / or transverse directions.

18. The method according to 16 or 17, characterized in that at least one light projection device (29a) of the lighting system (28) is used to visually indicate the location of the defect (27) on the upper surface of the upper layer, and the light projection device (29a) projects at least one light pattern onto the upper surface of the upper layer.

19. The method according to any one of claims 16 to 18, characterized in that the processor (26) analyzes the data in real time and / or the lighting system (28) visually indicates the location of the defect (27) in real time.

20. The method according to any one of claims 16 to 19, characterized in that the defects (27) are ranked by the processor (26) according to one or more predetermined conditions, and each ranking level is associated with a different color set and / or a different rhythm frequency.

21. The method according to any one of claims 16 to 20, characterized in that the composite structure (17) extends from a first end to a second end in the longitudinal direction and further extends from a first edge to a second edge in the width direction, and the measuring device (25) performs a scan of the upper surface as it moves along the longitudinal direction, and the scan is performed over at least a portion of the width of the composite structure (17) and / or over at least a portion of the length of the composite structure (17).

22. The method according to any one of claims 16 to 21, characterized in that at least one fiber material (33) layer is laminated on the upper layer and the upper surface is scanned at the same time.

23. The method according to any one of claims 16 to 22, characterized in that a scan of the upper surface is performed after laminating at least one fiber material (33) layer on the upper layer and optionally before laminating at least one further fiber material (33) layer.

24. The method according to any one of claims 16 to 23, further comprising the step of inputting at least one feedback signal to the processor (26), preferably via a graphic user interface, wherein the feedback signal indicates that at least one predetermined action has been performed with respect to a selected defect.

25. The method according to any one of claims 16 to 24, characterized in that after each scan, historical data relating to defects (27) in a specific layer of the composite structure (17) is stored in a database, and preferably, feedback signals input to the processor (26) are further stored in the database.

26. The method according to 25, characterized in that the processor (26) transmits historical data relating to defects (27) in at least one preceding layer to the lighting system (28), and the lighting device (29) visually displays the historical data together with current data relating to defects (27) in the upper layer, preferably.

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